Nonwoven composite

ABSTRACT

The application relates to a nonwoven composite containing a plurality of solid regions and a plurality of porous regions. The solid and porous regions form a repeating pattern on the surface of the composite. The solid regions contain a solid region nonwoven layer, an optional solid region polymer-fiber infused layer, and a solid region cap layer. The solid region nonwoven layer contains a plurality of first staple fibers and less than about 5% by volume of a first polymer. The solid region cap layer contains the first polymer and less than about 5% by volume of the first staple fibers. The porous regions contain a porous region nonwoven layer and a porous region polymer-fiber infused layer. The porous region nonwoven layer contains a plurality of the first staple fibers and less than about 5% by volume of a first polymer. The porous region polymer-fiber infused layer contains a plurality of pores.

FIELD OF THE INVENTION

The present invention generally relates to composites having soundabsorbing properties and methods of making and using such composites.

BACKGROUND

Sound absorbing materials are used in a number of applications withinthe transportation, building and construction, office and homefurnishing, and entertainment industries to enhance user experiences andreduce unwanted noise. Composite materials offer the opportunity to tunethe acoustic properties of sound absorbing materials for optimalperformance in specific applications while minimizing the overall partmass. In many of these applications it is also required that thematerial be molded into a specified shape and rigidity. In theautomotive industry, these types of moldable acoustic compositematerials are often used for applications such as wheel well liners,underbody shields, hood liners, firewall barriers, dash insulators, andflooring among others. In certain automotive applications, thesemoldable acoustic composite materials may require an aestheticallypleasing cover material be incorporated into the part.

There is a need for moldable acoustic nonwoven composite materialshaving improved and tailored acoustic properties, while retaining lowmaterial and manufacturing costs.

BRIEF SUMMARY

The application relates to a nonwoven composite having an upper surfaceand a lower surface where the upper surface and the lower surface definea composite thickness. The nonwoven composite contains a plurality ofsolid regions and a plurality of porous regions. The solid regions havean average size of greater than about 1 mm², the porous regions have anaverage size of greater than about 1 mm², and the porous regions andsolid regions form a pattern on the lower surface of the nonwovencomposite.

The solid regions contain a solid region nonwoven layer, an optionalsolid region polymer-fiber infused layer, and a solid region cap layer.

The solid region nonwoven layer has a first side and a second side,where the first side of the solid region nonwoven layer forms a portionof the upper surface of the nonwoven composite. The solid regionnonwoven layer contains a plurality of first staple fibers and less thanabout 5% by volume of a first polymer.

The solid region polymer-fiber infused layer has a first side and asecond side, where the solid region polymer-fiber infused layer isoriented such that the first side of the solid region polymer-fiberinfused layer is adjacent to the second side of the solid regionnonwoven layer. The solid region polymer-fiber infused layer contains aplurality of the first staple fibers and the first polymer.

The solid region cap layer has a first side and a second side and isoriented such that the first side of the solid region cap layer isadjacent to the second side of the solid region polymer-fiber infusedlayer or the second side of the solid region nonwoven layer. The secondside of the solid region cap layer forms a portion of the lower surfaceof the nonwoven composite. The solid region cap layer contains the firstpolymer and less than about 5% by volume of the first staple fibers andthe average distance between first and second sides of the solid regioncap layer is greater than about 65 μm.

The porous regions contain a porous region nonwoven layer and a porousregion polymer-fiber infused layer.

The porous region nonwoven layer has a first side and a second side andforms a portion of the upper surface of the nonwoven composite. Theporous region nonwoven layer contains a plurality of the first staplefibers and less than about 5% by volume of a first polymer.

The porous region polymer-fiber infused layer has a first side and asecond side and is oriented such that the first side of the porousregion polymer-fiber infused layer is adjacent to the second side of theporous region nonwoven layer and the second side of the porous regionpolymer-fiber infused layer forms a portion of the lower surface of thenonwoven composite. The porous region polymer-fiber infused layercontains a plurality of the first staple fibers and at least 15% byvolume first polymer. The porous region polymer-fiber infused layercontains a plurality of pores, where the pores provide a continuous pathfor air to transport from the first side to the second side of theporous region polymer-fiber infused layer.

The application also relates to a process for forming a nonwovencomposite. The process contains the step of forming a nonwovencontaining a plurality of first fibers and having a first surface and anopposite second surface, where the first surface and the second surfacedefine a nonwoven layer thickness. The process also contains the stepsof obtaining at least a first polymer, where the first polymer is athermoplastic polymer and applying the first polymer (in molten,semi-molten, or solid state) to the second surface of the nonwoven. Theprocess further contains the step of applying pressure and optionallyheat to the nonwoven and the at least first polymer, where the firstpolymer and the second surface of the nonwoven are subjected to apatterned textured surface which embeds a portion of the first fibersfrom the nonwoven into the first polymer. The first polymer is cooled,forming a nonwoven composite.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustrative cross-section of one embodiment of thenonwoven composite.

FIG. 2 is a micrograph of the cross-section of one embodiment of thenonwoven composite focusing on a solid region.

FIG. 3 is a micrograph of the cross-section of one embodiment of thenonwoven composite focusing on a porous region.

FIGS. 4-6 are top-view micrographs of one embodiment of the nonwovencomposite at different magnifications.

FIG. 7 is a plot of the sound absorption coefficients of severalexamples.

FIGS. 7A and 7B are illustrative views looking at the lower surface ofthe composite.

DETAILED DESCRIPTION

The present disclosure is directed to moldable acoustic composites thatprovide acoustical properties including, but not limited to, soundabsorption properties and sound barrier properties. The nonwovencomposite (1) has positive sound absorption properties; (2) hasstructural features that enable their use in a variety of applications;and (3) can be manufactured in a cost-effective manner.

Referring to FIG. 1, there is shown a cross-sectional illustration ofone embodiment of the nonwoven composite 10. The nonwoven composite 10contains at least 2 types of regions, a solid region 100 and a porousregion 200. The nonwoven composite has an upper surface 10 a and a lowersurface 10 b. The distance between these two surfaces 10 a, 10 b is thenonwoven composite thickness.

The nonwoven composite 10 may contain additional regions besides thesolid regions 100 and the porous regions 200 such as transitionalregions between the two regions 100, 200. In one embodiment, thenonwoven composite preferably contains a plurality of wall regionslocated between the solid regions and porous regions which aretransitional regions between the solid and porous regions 200. The wallregions may contain physical characteristics of both the solid andporous regions. The solid regions have an average first porosity and theporous regions have a second porosity and preferably the second porosityis at least 1000% greater than the first porosity. Pores are defined asa continuous path for the transport of air through a layer or a regionof the nonwoven composite.

Preferably, the solid regions 100 have an average surface area size(when viewed normal to the lower surface 10 b of the nonwoven composite)of greater than about 1 mm², more preferably greater than about 5 mm²,most preferably greater than about 10 mm². Preferably, the porousregions 200 have an average surface area size (when viewed normal to thelower surface 10 b of the nonwoven composite) of greater than about 1mm², more preferably greater than about 5 mm², and most preferablygreater than about 10 mm².

Preferably, the solid regions 100 and/or the porous regions 200 are in apattern. The pattern may be continuous or discontinuous, regular andrepeating or random. Preferably, the pattern is repeating. “Continuous”in this application means that from one edge of the composite to theother edge there is a continuous path of either solid regions 100 orporous regions 200. Some continuous patterns include linear stripes,grids, a rectilinear grid, and wavy lines. “Discontinuous” in thisapplication means that from one edge of the composite to the other edgethere is not a path of either solid regions 100 or porous regions 200.Examples of discontinuous patterns include dots, most indicia, text, andshort random lines. Preferably, the presence of the solid regions 100 orporous regions 200 on the lower surface 10 b of the composite 10 is notvisibly evident when looking at the upper surface 10 a of the composite10. In one example of a pattern of the solid regions comprising a seriesof repeating dots, the solid regions would be in a discontinuous patternand the porous regions would be in a continuous, repeating pattern (theinverse of the dot pattern).

Referring now to FIGS. 7A and 7B, which are two different illustrationsof different patterns of solid regions and porous regions that can beseen on the lower surface of the composite. In these illustrations, theregions 1000 may be solid regions or porous regions (with the regions2000 being the inverse region). In a preferred embodiment, the regions1000 are the solid regions and the regions 2000 are the porous regions.

One example, shown in FIG. 7A, shows a pattern of lines forming a grid.The lines are the regions 2000 and the square-like shapes are theregions 1000. The smallest dimension 2001 of the line regions 2000within pattern is the width of the lines. The smallest dimension 1001 ofthe square like grid regions 1000 is the width of the square shape.

Another example, shown in FIG. 7B, shows a pattern of repeating dots.The spacing between the dots are the regions 2000 and the dot shapes arethe regions 1000. The smallest dimension 2001 is the distance betweenthe dots. The smallest dimension 1001 of the dot regions 1000 is thediameter of the dots.

Preferably, the smallest dimension of the porous regions of the patternwhen viewed normal to the lower surface 10 b of the nonwoven compositeis at least as wide as the solid region cap layer thickness. Morepreferably, the smallest dimension of the porous regions of the patternis at least twice the thickness of the solid region cap layer. Thesmallest dimension of the pattern is preferably greater than 0.1 mm,more preferably greater than 0.2 mm, and most preferably greater than0.3 mm.

The pattern of solid and porous regions on the lower surface of thenonwoven composite can be seen in photomicrographs in FIGS. 4-6. FIGS.4-6 are of the same nonwoven composite taken with increasingly highmagnification. As one can see in FIG. 4, the porous regions are in acontinuous linear design and the solid regions form discontinuoussquare-like shapes. It is possible to create the inverse of this patternalso, with the solid regions being the continuous linear grid. The poreopenings in FIGS. 4-6 are typically smaller than the voids presentbetween the fibers in the uncoated nonwoven because the first polymerbridges and coats the fibers. Three dimensionally, each pore istypically more constrained to air flow since air can no longer spreadout as soon as it passes the fiber. Therefore, higher air flowresistance can be achieved.

The porous regions 200 of the composite 10 can range from about 5% to80% of the total surface area of the lower surface 10 b of the composite10, preferably between about 20% and 60%. In one embodiment, thesmallest dimension of the porous regions are at least 3 times as wide asthe average spacing between fibers on the lower surface 10 b of thecomposite 10. Preferably, the porous regions 200 are narrower than 3times the composite 10 thickness, more preferably narrower than 1 timesthe composite thickness.

The relative surface area of porous regions 200 and solid regions 100may be tailored to the end use according to the required structuralproperties, durability properties (resistance to abrasion, chipping,etc.), barrier properties (permeability to air and other fluidsincluding water, oil, etc), surface attachment properties such as iceand dirt, surface release properties, and acoustic properties includingsound absorption and sound barrier requirements. In one embodiment, thenonwoven composite 10 comprises about 50% by surface area of porousregions. In another embodiment, the nonwoven composite 10 comprises lessthan about 30% by surface area of porous regions. In another embodiment,the nonwoven composite 10 comprises less than about 10% by surface areaof porous regions.

The process of making the nonwoven composite begins with creating anonwoven (which will eventually form a portion of layers 110, 120, 210,220, and to a small extent 130).

The nonwoven may be formed by any suitable method including, but notlimited to carding or garneting, air laying, cross-lapping, needling,structuring, stitching, and bonding. The nonwoven contains a pluralityof first staple fibers as well as optional fibers such as binder fibers,additional staple fibers, and other effect fibers (defined as any fiberhaving an “effect” such as bulking, color, antistatic, etc.).

Preferably, the nonwoven is formed by carding, cross-lapping, andneedle-punching, and optionally thermal bonding a plurality of firststaple fibers, optional binder fibers, and other staple fibers. Thenonwoven preferably has a thickness between about 1 and 25 mm and morepreferably a thickness between about 1 and 8 mm. The nonwoven preferablyhas an areal density of between about 100 and 2000 g/m² and morepreferably between about 250 and 1000 g/m². In one embodiment, thenonwoven is substantially and generally uniform in fiber weightpercentages, areal weights, and areal densities across the nonwoven (inall three directions). In one embodiment, the first staple fiberscomprise about 40% of the total fiber volume in the nonwoven, preferablybetween 50 and 100% of the total fiber volume in the nonwoven, and morepreferably between about 60 and 95% of the total fiber volume in thenonwoven.

In one embodiment, the upper surface 10 a of the nonwoven is formed intoa random velour. To create the random velour, the nonwoven is passedover a brush apparatus having a series of projections and intersticesbetween the projections. This random velour look is desirable as whenused as an A surface (the surface of the composite accessible in thefinal application) for end uses such as car interiors. Preferably, therandom velour has a pile height of at least about 2 millimeters.

The first staple fibers of the nonwoven are fibers that provide mass andvolume to the material. The first staple fibers provide volume or bulkor loft in the Z-direction. For the purposes of this application, theZ-direction of the nonwoven is defined as the direction orthogonal tothe planar direction of the nonwoven. The planar direction means in aplane parallel to the first and second sides of the nonwoven. The firststaple fibers can include virgin and recycled fibers, high crimp fibers,hollow-fill fibers, circular and non-circular cross-section fibers,conjugated fibers, and other common staple fibers or a blend thereof.Some examples of first staple fibers include polyester, polypropylene,nylon, cotton, and wool as well as other staple fibers. In a preferredembodiment, the first staple fibers comprise polyester. Preferably, thefirst staple fibers have an average denier of approximately 1 to 20,more preferably 1.5 to 12 denier, and most preferably 3 to 9 denier. Inone embodiment, the fibers have a circular cross section. In anotherembodiment, fibers have higher surface area or noncircular cross sectionsuch as segmented pie, multi-lobal, winged fibers, tri-lobal, etc. Ithas been shown that the fiber denier, crimp, and cross-section influencethe sound absorption properties of the nonwoven. Optionally, additionalstaple fibers of different average denier or cross section may be addedto improve the mechanical properties of the nonwoven such as tensilestrength, tear strength, or compression resistance, or to improve otherproperties such as acoustic absorption, etc.

In addition to the first staple fibers 400 in the nonwoven, the optionalbinder fibers of the nonwoven are fibers that adhere to and bond withthe other fibers. Binder fibers can include fibers that are heatactivated, meaning that all or some portion of the fiber can soften ormelt at a lower temperature than the first staple fiber. When activatedby heat or other means, the binder fibers create fused bond points orwelds between adjacent fibers that create a network of interconnectedfibers. The binder fibers are preferably staple fibers. Examples of heatactivated binder fibers include low melt fibers and bi-component fibers,where one of the components of the fiber melts at a lower temperature.Example of bicomponent fiber geometries include side-by-side or core andsheath fibers and the like. In one embodiment, the binder fibers are apolyester core-and-sheath fiber with a sheath that melts at a lowertemperature than the core. A benefit of using a heat activated binderfiber as the binder fiber in the nonwoven is that the nonwoven compositecan be subsequently thermally molded into a three-dimensional shape foruse in automotive floors, wheel well liners, underbody shields, hoodliners, engine compartment covers, ceiling tiles, office panels, etc.The low melt fiber or portion of the fiber acts as an adhesive thatholds the molded part in its final shape after it has been removed fromthe mold and cooled to room temperature. In some embodiments, in thefinal product the binder fibers may lose some or all of their fibershape. Another benefit of binder fibers in the nonwoven is to improveabrasion resistance of the exposed nonwoven.

Preferably, when the nonwoven composite 10 is subjected to an additionalheat cycle and then cooled, the binder fibers remain as discernablefibers. In another embodiment, when the nonwoven composite 10 isconsolidated, the binder fibers lose their fiber shape and form acoating on surrounding materials. Preferably, the optional binder fibershave an average denier less than or about equal to 15 denier, morepreferably less than about 6 denier, and most preferably 4 denier orless.

Any other suitable fiber may also be used in the nonwoven in addition tothe first staple fibers 400 and optional binder fibers describedpreviously. These may include, but are not limited to, an additionalbinder fiber having a different denier, staple length, crimp,cross-sectional shape, composition, or melting point or a bulking fiberhaving a different denier, staple length, or composition, or a fireresistant or fire retardant fiber. The fiber may also be an effectfiber, providing a desired aesthetic or function. These effect fibersmay be used to impart color, chemical resistance (such as polyphenylenesulfide fibers and polytetrafluoroethylene fibers), moisture resistance(such as polytetrafluoroethylene fibers and topically treated polymerfibers), heat resistance (such as glass or ceramic fibers), fireresistance, or others.

In one embodiment, the nonwoven contains fire resistant fibers. Thesefire resistant fibers may also act as the bulking fibers or may be usedin addition to the bulking fibers. As used herein, fire retardant fibersshall mean fibers having a Limiting Oxygen Index (LOI) value of 20.95 orgreater, as determined by ISO 4589-1. Types of fire retardant fibersinclude, but are not limited to, fire suppressant fibers and combustionresistant fibers. Fire suppressant fibers are fibers that meet the LOIby consuming in a manner that tends to suppress the heat source. In onemethod of suppressing a fire, the fire suppressant fiber emits a gaseousproduct during consumption, such as a halogenated gas. Examples of fibersuppressant fibers include modacrylic, PVC, fibers with a halogenatedtopical treatment, and the like. Combustion resistant fibers are fibersthat meet the LOI by resisting consumption when exposed to heat.Examples of combustion resistant fibers include silica impregnated rayonsuch as rayon sold under the mark VISIL®, partially oxidizedpolyacrylonitrile, polyaramid, para-aramid, carbon, meta-aramid,melamine and the like.

Some or all of the fibers (first staple fiber 400, optional binderfibers, additional fibers) may additionally contain additives within thefibers or as topical coatings or fiber finishes. Suitable additivesinclude, but are not limited to, fillers, stabilizers, plasticizers,tackifiers, hydrophobic agents, flow control agents, cure rateretarders, adhesion promoters (for example, silanes and titanates),adjuvants, impact modifiers, expandable microspheres, thermallyconductive particles, electrically conductive particles, silica, glass,clay, talc, pigments, colorants, glass beads or bubbles, antioxidants,optical brighteners, antimicrobial agents, surfactants, fire retardants,and fluoropolymers. One or more of the above-described additives may beused to reduce the weight and/or cost of the resulting fiber and layer,adjust viscosity, or modify the thermal properties of the fiber orconfer a range of physical properties derived from the physical propertyactivity of the additive including electrical, optical, density-related,liquid barrier or adhesive tack related properties.

The network of fibers in the nonwoven interact through entanglement andbonding to provide integrity, strength, and resiliency when the loftynonwoven is exposed to forces. In the planar direction of the loftynonwoven, the degree of entanglement and bonding can be measured by thetensile properties of the nonwoven layer.

Another characteristic of the nonwoven is the tendency for the materialto deform in the Z-direction when a compression force is applied andrecover its original shape after the compression force is removed.Preferably, the volumetric porosity of at least a portion of thenonwoven is greater than about 25%, more preferably greater than about50%. The volumetric porosity is defined as the volume percentage of thenonwoven occupied by air (or other gas). These levels of porosity inlofty nonwovens will enable Z-direction compression and recoveryproperties well suited for many applications such as floor underlayment,carpet padding, and furnishings. Different nonwovens with differentcombinations of non-uniform fiber orientations, fiber contact points,discrete bond points, and bulk densities results in materials thatexhibit different levels of compression and recovery behavior whenexposed to Z-direction compression forces. For example, a looselyconnected network of low stiffness or small diameter fiber may have avery low compression resistance and compression recovery while a moredensely connected network of stiff fibers may offer higher compressionresistance and recovery. These compression and recovery properties mayplay a critical role in how the material behaves when exposed to furtherprocessing steps such as coating, lamination, heating and molding.

The nonwoven may also be formed with a non-uniform distribution of fibertypes through the nonwoven thickness. One embodiment is a stratifiednonwoven with one side containing primarily large denier fibers and asecond side containing primarily small denier fibers. Another embodimentis a structured nonwoven with a first face side and a second back side.In this embodiment, the face side is characterized by loops or fibertufts wherein the fiber axis is generally oriented about in theZ-direction while the back side contains similar or dissimilar fiberswhere the general orientation is approximately in the planar directionof the nonwoven. An example of one such embodiment would be the nonwovencarpets commonly used in automotive floors which often comprise a faceand a back side.

After the nonwoven is formed, a first polymer is obtained that will beused to form parts of the upper areas within the composite 10. The firstpolymer may be any suitable thermoplastic polymer such as one that has asoftening point or melting point near or sufficiently below the meltingor softening point of the polymer used to make the first staple fibersin the nonwoven so that the first staple fibers in the nonwoven do notmelt or shrink excessively when the first polymer is applied to itthrough heat and/or pressure or when the part is optionally heated tosoften the first polymer, as often occurs when molding the nonwovencomposite. In one embodiment, for a nonwoven of predominatelypolyethylene terephthalate (polyester or PET) first stable fibers, lowdensity polyethylene (LDPE) is a suitable choice for the first polymer.The first polymer can include but is not limited to polyethylene,polypropylene, polybutylene, polyvinyl chloride, poly (ethylene-co-vinylacetate), nylon, polyethylene terephthalate, and polybutyleneterephthalate. Also suitable for the first polymer would be the generalclass of thermoplastic elastomers, thermoplastic vulcanizates,thermoplastic polyurethanes, and copolymers or blends of anythermoplastic polymer with additional polymers, processing aids,viscosity modifiers, fillers, density modifying agents, blowing agents,IR active materials, adhesion modifiers, stabilizers or other additives.

To form the nonwoven composite 10, the first polymer is applied to thenonwoven in the molten, semi-molten, or solid state. The process furthercontains the step of applying pressure and optionally heat to thenonwoven and the first polymer (or polymer blend), where the firstpolymer (or blend) and the second surface of the nonwoven are subjectedto a patterned textured surface which embeds a portion of the firstfibers from the nonwoven into the first polymer, thereby bonding themtogether. The high points of the textured surface correspond to theporous regions (which are formed in a subsequent operation) in thenonwoven composite, while the low points of the textured surfacecorrespond to the solid regions of the nonwoven composite. Therefore,the patterned textured surface has an inverse profile from the desiredpattern of the porous and solid regions of the nonwoven composite.

Application of the pressure and optionally heat occurs as the firstpolymer is being applied to the nonwoven or after the first polymer isapplied. The nonwoven composite 10 is then cooled such that the firstpolymer at least partially solidifies. This cooling preferably happenswhile the first polymer is in contact with the patterned texturedsurface as to preserve the texture in the composite 10. In oneembodiment, the application of first polymer and subjecting the firstpolymer and nonwoven to pressure (and optionally heat) takes placeapproximately simultaneously. In another embodiment, the application offirst polymer and subjecting the first polymer and nonwoven to pressure(and optionally heat), and then cooling the composite takes placeapproximately simultaneously.

One preferred method of applying the first polymer to the nonwoven andsubjecting the combination to the patterned textured surface is bybringing the nonwoven into a nip which contains a patterned rollerhaving a textured surface and a pressure roller, and extruding moltenfirst polymer either onto the nonwoven before it enters the nip, ontothe nonwoven right at the nip, or onto the patterned textured rollerclose to the nip. The patterned textured roller creates the plurality ofporous regions and the plurality of solid regions. Typically, thetextured roller would be chilled (by cooling water or the like) suchthat the first polymer at least partially solidifies into the inverse ofthe textured surface of the roller before the now composite nonwoven 10leaves the nip.

In another embodiment, the at least first polymer is applied to thenonwoven as a free standing, solid film. This film may be placed on thenonwoven and then heat and pressure are applied via a patterned texturedsurface such that the film is at least partially melted and conforms tothe textured surface. The composite is then cooled preferably while thefilm is in contact with the textured surface as to preserve the texturein the composite 10.

The step of using pressure (and optionally heat) while subjecting thefirst polymer to the patterned textured surface creates regions in thematerial that lead to the plurality of solid regions 100 and pluralityof porous regions 200 in the composite 10. The solid regions 100 areidentified by the planar-like portions of the composite surface 10 bcorresponding to the areas of maximum nonwoven composite thickness. Theporous regions are identified by the planar-like portions of thecomposite surface 10 b where the nonwoven composite thickness isreduced. The measured difference in nonwoven composite thickness betweenthe solid and porous regions is referred to as the indentation depth.

Once the nonwoven composite 10 is formed, it may be treated to anadditional step(s) of adding heat and optionally pressure. Thetemperature of the heat exposure can be chosen so that it exceeds therelaxation temperature of the nonwoven and the softening or meltingpoint of the first polymer but is below the softening or melting pointof the first staple fiber. As a result of this additional exposure toheat, the porous regions 200 develop porosity. While not being bound toany theory, it believed that while the first polymer and nonwoven arebeing subjected to pressure (and optionally heat) to form the nonwovencomposite 10, a portion of the first polymer infuses into the nonwoven,encapsulating some fibers and compressing the nonwoven. In addition,during this process a portion of the first polymer is moved from theareas that will become the porous regions to the areas that will becomethe solid regions due to the pattern on the roller. The additionalstep(s) of adding heat softens or melts the first polymer and may enablethe compressed areas of the nonwoven layer to relax and spring back. Theforces that drive the relaxation and spring back behavior of thenonwoven layer include residual mechanical stresses, residual thermalstresses, and polymer shrinkage. The relative motion among the fibers inthe nonwoven layer as it relaxes and springs back exert a shearingaction on the softened or molten first polymer locally between and amongthe encapsulated fibers. The shearing action exerted on the firstpolymer by the encapsulated fibers is sufficient to open pores throughthe thickness of the porous region polymer-fiber infused layer 220 butnot through the solid region cap layer 130.

The solid regions 100 comprise a solid region nonwoven layer 110, anoptional solid region polymer-fiber infused layer 120, and a solidregion cap layer 130. The layers are characterized by their compositionand may not have distinct boundaries. A photomicrograph of thecross-section of one solid region can be seen in FIG. 2. In the solidregions 100, there is essentially no porosity due to the cap layer. Inone preferred embodiment, the solid regions do contain a solid regionpolymer-fiber infused layer 120, but typically the solid regionpolymer-fiber infused layer 120 is much thinner than the solid regioncap layer 130 and the solid region nonwoven layer 110.

The solid region nonwoven layer 110 has a first side 110 a and a secondside 110 b. The first side 110 a of the solid region nonwoven layer 110forms a portion of the upper surface 10 a of the nonwoven composite 10.The solid region nonwoven layer 110 is mostly the nonwoven with littleto no first polymer. Preferably, the solid region nonwoven layer 110comprises less than about 5% by volume of the first polymer 300. Thevolume percentage of a component is measured by taking a cross-sectionalimage of the nonwoven composite and measuring the surface area on thatcross-section. The percentage of area taken up by a component in thecross-sectional image is considered to be equivalent to the volumepercentage of that component in the vicinity of the area surveyed.

The solid region cap layer 130 has a first side 130 a and a second side130 b. The solid region cap layer 130 is oriented such that the firstside 130 a of the solid region cap layer 130 is adjacent second side 120b of the solid region polymer-fiber infused layer 120 or the second sideof the solid region nonwoven layer 110 b, and the second side 130 b ofthe solid region cap layer forms a portion of the lower surface 10 b ofthe nonwoven composite 10. The solid region cap layer 130 comprises thefirst polymer 300 and less than about 5% by volume of the first staplefibers, optional binder fibers, and other fibers of the nonwoven.Preferably, the solid region cap layer 130 comprises the first polymer300 and less than about 5% by volume fibers (all fibers). Preferably,the solid region cap layers 130 comprise essentially no pores 221.Preferably, the average distance between first and second sides, 130 aand 130 b, of the solid region cap layer 130 is greater than about 65μm. Preferably, the solid region cap layer 130 comprises essentially nofibers from the nonwoven layer.

Located between the solid region nonwoven layer 110 and the solid regioncap layer 130 is an optional solid region polymer-fiber infused layer120. This polymer-fiber infused layer 120 is a transitional region whichhas some of the characteristics of both the nonwoven layer 110 and thecap layer 130. The solid region polymer-fiber infused layer 120 isoriented such that the first side 120 a of the solid regionpolymer-fiber infused layer 120 is adjacent to the second side 110 b ofthe solid region nonwoven layer 110 and that the second side 120 b ofthe solid region polymer-fiber infused layer 120 is adjacent to thefirst side 130 a of the solid region cap layer 130. The solid regionpolymer-fiber infused layer 120 comprises a plurality of the firststaple fibers 400, optional binder and other fibers, and the firstpolymer 300 and at least a portion of the first staple fibers 400 areembedded into the first polymer 300. Physical intermingling of firststaple fibers 400 and first polymer 300 ensures strong adhesion betweenthe layers. As a transitional region, the solid region polymer-fiberinfused layer 120 tends to be thinner (defined as the distance betweenthe first and second sides 120 a, 120 b) than the solid region cap layer130 or the solid-region nonwoven layer 110.

The porous regions 200 comprise a porous region nonwoven layer 210 and aporous region polymer-fiber infused layer 220. The layers arecharacterized by their composition and may not have distinct boundaries.A photomicrograph of the cross-section of one porous region can be seenin FIG. 3.

The porous region nonwoven layer 210 is essentially the same as thesolid region nonwoven layer 110 and both are formed from the samenonwoven layer used to make the composite 10. The porous region nonwovenlayer 210 has a first side 210 a and a second side 210 b, where thefirst side 210 a of the porous region nonwoven layer 200 forms a portionof the upper surface 10 a of the nonwoven composite 10. The porousregion nonwoven layer 210 comprises a plurality of first staple fibers400, optional binder fibers and other fibers and less than about 5% byvolume of first polymer 300.

The porous region 200 also contains the porous region polymer-fiberinfused layer 220 which has a first side 220 a and a second side 220 b,where the porous region polymer-fiber infused layer 220 is oriented suchthat the first side 220 a of the porous region polymer-fiber infusedlayer 200 is adjacent the second side 210 b of the porous regionnonwoven layer 210 and the second side 220 b of the porous regionpolymer-fiber infused layer forms a portion of the lower surface 10 b ofthe nonwoven composite 10. The porous region polymer-fiber infused layer220 comprises a plurality of the first staple fibers 400 and the firstpolymer 300. The porous region polymer-fiber infused layer 220 is formedwhen the first polymer is applied with pressure and optionally heat tothe nonwoven such that the first polymer infuses into a portion of thenonwoven.

The porous region polymer-fiber infused layer 220 comprises a pluralityof pores 221, the pores being defined as having a continuous path forair to move from the first side 220 a to the second side 220 b of theporous region polymer-fiber infused layer 220. These pores 221 enablethe porous regions 200 to be porous. The pores may be in the porousregion polymer-fiber infused layer 220 directly after the heat andpressure step, or may form during or after subsequent heating cycles.The first polymer in the porous region polymer-fiber infused layer 220forms a coating between and spanning across the fibers, which reducesthe pore size and volumetric porosity of the layer relative to theoriginal uncoated nonwoven. The nature of the porosity in the porousregion polymer-fiber infused layer 220, due to the infused firstpolymer, is therefore different than in the uncoated nonwoven. Incontrast, a mechanically perforated film attached to a nonwoven does notprovide reduced pore size in the porous areas, where the porosity is thesame as that of the underlying nonwoven.

The pores 221 are typically smaller than 0.5 mm along their largestdimension measured within the plane of the composite 10 (width ordiameter), more preferably smaller than 0.2 mm. In one embodiment, thenumber average pore size is under 0.06 mm and half of the pore area isprovided by pores with less than 0.12 mm diameter. The average pore sizeis related to the average distance between fibers in the nonwoven andthe degree of relative motion that occurs between encapsulated fibersduring the heating step(s). Pores 221 with dimensions on this scale areknown to provide excellent sound absorption due to their ability todissipate sound energy in a viscous boundary layer as the sound pressurewaves move air through the pores. Pores of these dimensions may bedifficult to form through common means such as mechanical perforation.Since the pore size and shape is influenced and partially controlled bythe inter-fiber spacing in the nonwoven, the pores remain relativelysmall and stable when exposed to excess heat. In contrast, holes inconventional mechanically perforated films tend to close or grow rapidlywhen exposed to heat above the film's softening temperature.

Preferably, the porous region polymer-fiber infused layer 220 containsbetween about 15 and 85% by volume first staple fibers, about 15 and 85%by volume first polymer, and about 5 and 50% by volume air. Morepreferably between about 20 and 60% by volume first staple fibers, about40 and 80% by volume first polymer, and about 5 and 20% by volume air.Considering just the solid parts of the porous region polymer-fiberinfused layer 220 (excluding any air filled open spaces within thelayer), the solid parts of the layer preferably include between about 15and 85% by volume first staple fibers and between about 15 and 85% byvolume first polymer, more preferably between about 20 and 60% by volumefirst staple fibers and between about 40 and 80% by volume firstpolymer. In one embodiment the volume ratio between all of the polymerand all of the fibers within the layer is between about 50:50 and 80:20.

In one embodiment, the volume fraction of total fibers in the in theporous region polymer-fiber infused layer 220 is preferably less thanabout 70% by volume, more preferably less than about 50% by volume, morepreferably less than about 30% by volume.

A patterned surface of solid and porous regions (100, 200), where theporous regions 200 have a greater porosity than the solid regions 100,has numerous benefits. The solid film nature of the cap layer of thesolid regions provides enhanced structural properties, durabilityproperties (resistance to abrasion, chipping, etc.), barrier properties(impermeability to air and other fluids including water, oil, etc), andsurface detachment properties from materials such as ice and dirt. Thecap layer of the solid regions provides an accessible area for bondingof additional layers to the composite without disturbing the porositycreated in the porous regions of the composite and the cap layer of thesolid regions, when heated, can act as the adhesive material. In termsof acoustic performance, the solid regions act primarily as barrierregions while the porous regions are highly sound absorbing. Thecombination of solid and porous regions also enables a more drapablecomposite that can be molded with fewer wrinkles.

In one embodiment, an additional nonwoven layer is attached to thecomposite (preferably on the lower surface of the composite 10). Thisadditional nonwoven layer preferably has a thickness greater than thethickness of the composite 10. This additional nonwoven layer issometimes referred to in the automotive industry as a sound absorbing orshoddy layer. The sound absorbing layer can be added to a composite toprovide additional acoustic absorption, barrier properties, orvibrational damping properties to the total system, leading to betteroverall performance. The additional nonwoven layer can be attached byany suitable means such as adhesive or fasteners. In a differentembodiment, the shoddy can serve as the nonwoven layer which forms aportion of the composite 10.

The nonwoven composite 10 may also contain any additional layers forphysical or aesthetic purposes. Suitable additional layers include, butare not limited to, nonwoven fabrics, woven fabrics, tufted fabrics,knitted fabrics, foam layers, films, paper, adhesive-backed layers,foils, meshes, elastic fabrics (i.e., any of the above-described woven,knitted or nonwoven fabrics having elastic properties), apertured webs,or any combination thereof. Other suitable additional layers include,but are not limited to, a color-containing layer (e.g., a print layer);one or more additional sub-micron fiber layers having a distinct averagefiber diameter and/or physical composition; one or more secondary finefiber layers for additional insulation or acoustic performance (such asa melt-blown web or a fiberglass fabric); layers of particles;decorative fabric layers; membranes (i.e., films with controlledpermeability, such as dialysis membranes, reverse osmosis membranes,etc.); netting; wiring and tubing networks (i.e., layers of wires forconveying electricity or groups of tubes/pipes for conveying variousfluids, such as wiring networks for heating blankets, and tubingnetworks for coolant flow through cooling blankets); or a combinationthereof. The additional layers may be on either or both sides of thenonwoven composite. For example, a textile may be applied to one side ofthe nonwoven composite using an optional adhesive layer to form anaesthetic surface for an end use such as certain automobileapplications.

In another embodiment, the nonwoven composite 10 is molded into a threedimensional shape for use as a durable exterior vehicle part where thelower surface of the composite 10 faces away from the vehicle.Additional nonwoven layers may be attached to the composite 10,preferably to the upper surface of the molded composite. Theseadditional nonwovens layers can be added to a composite to provideadditional acoustic absorption, barrier properties, or vibrationaldamping properties to the total system, leading to better overallperformance. The additional nonwoven layers can be attached by anysuitable means such as adhesive or fasteners.

The nonwoven composite 10 may further comprise one or more attachmentdevices to enable the composite 10 to be attached to a substrate orother surface. In addition to adhesives, other attachment devices may beused such as mechanical fasteners like screws, nails, clips, staples,stitching, thread, hook and loop materials, etc.

The one or more attachment devices may be used to attach the composite10 to a variety of substrates. Exemplary substrates include, but are notlimited to, a vehicle component; an interior of a vehicle (i.e., thepassenger compartment, the motor compartment, the trunk, etc.); a wallof a building (i.e., interior wall surface or exterior wall surface); aceiling of a building (i.e., interior ceiling surface or exteriorceiling surface); a building material for forming a wall or ceiling of abuilding (e.g., a ceiling tile, wood component, gypsum board, etc.); aroom partition; a metal sheet; a glass substrate; a door; a window; amachinery component; an appliance component (i.e., interior appliancesurface or exterior appliance surface); a surface of a pipe or hose; acomputer or electronic component; a sound recording or reproductiondevice; a housing or case for an appliance, computer, etc.

Test Methods

The air permeability of the nonwoven composite 10 can be measured byASTM D737. The standard calls for clamping a material sample to the testmachine with a minimum force of 50 N and adjusting the airflow rateperpendicularly through the sample until a prescribed pressureddifferential is established. Once steady state is reached, the observedairflow rate at the prescribed pressure differential is used todetermine the air permeability of the material. The test standard allowsfor a range of pressures to be used between 100 and 2500 Pa, butrecommends use of 125 Pa unless otherwise specified. Therefore, airpermeability of nonwovens composites is reported herein at 125 Pa withthe upper surface of the composite in contact with the orifice of theair permeability tester.

US patent application 20040038046 details a testing device formeasurement of the load required for sliding movement of ice and forexamination of the condition of the ice sliding movement on solidsurfaces. A modified version of this test method is used here to measurethe normal force required to detach ice from non-woven substrates. Thesample size used is 150 mm×80 mm. A circular metal cylinder is placed ontop of the sample. The cylindrical fixture has a circular hook welded tothe surface of the cylinder. Water is poured into the cylindricalfixture and kept in a freezer at −15° C. for 150 minutes. To preventbreaking/cracking of ice due to expansion, the water needs to be icedgradually. At the end of 150 minutes, a force gage is attached to thehook and the normal force required to remove the fixture from thesurface of the non-woven is measured. The appearance of the sampleimmediately after ice detachment is recorded (any fiber separation ordelamination).

The acoustic performance of the examples was evaluated by measuring thesound absorption coefficient using random incident sound absorptiontesting based on the SAE J2883 test standard. The chamber used formeasuring was a 25.0 m³ reverberation room. Guidance as to the aspectratio of the length to width to height for the room was provided in ISO3741. Samples were mounted to the floor, using 1.0 by 1.2 m size panelswith the upper surface in contact with the floor.

EXAMPLES Example 1

The nonwoven of example 1 was formed by carding, cross-lapping,needle-punching, and thermally bonding a plurality of first staplefibers with other fibers. The first staple fibers, 6 denier PET,comprised 57% of the total fiber volume in the nonwoven, while 4 deniercore/sheath PET binder fibers comprised 29% of the total fiber volume inthe nonwoven and 8 denier polypropylene fibers comprised 14% of thetotal fiber volume. The nonwoven had a thickness between about 3 and 4mm and an areal density of about 700 g/m².

Example 2

The nonwoven of example 1 was coated with 300 g/m² of 12 melt flow rate(MFR) low density polyethylene (LDPE) using a standard extrusionlamination process. The nonwoven was roll fed into a nip formed by apatterned textured chill roller and a pressure roller such that thelower side of the nonwoven faced the textured chill roller and the upperside faced the pressure roller. Molten LDPE was applied to the lowerside of the nonwoven at the nip. The chill roll was patterned with araised grid design, where the high points of the textured surface werecontinuous and linear, and the low points were square-like anddiscontinuous. The squares were approximately 4 mm on each side and thegrid lines were approximately 1 mm in width and 1 mm in depth. Aninverse texture of the chill roll was imparted to the lower side of thenonwoven, meaning that the raised grid of the patterned nip resulted ina nonwoven composite with raised 4-mm squares and a recessed 1-mm widegrid pattern. The recessed grid of the nonwoven composite corresponds tothe formation of the porous regions 200, while the raised squarescorrespond to the formation of solid regions 100. In the solid regions100, the solid region cap layer 130 had an average thickness of about0.3 mm.

The nonwoven composite of Example 2 was heated by an infrared heater toa surface temperature of approximately 350° F. while constrained by aframe around all 4 sides, then cooled to near room temperature beforeremoving from the frame. After the heating and cooling, the nonwovencomposite exhibited a plurality of micropores in the porous regions andthe porosity in the solid regions was essentially zero, meaning no poreswere found in the solid regions over the area surveyed. After heating,the solid regions look substantially unchanged from the unheated Example2, that is, the cap layer porosity remains essentially zero. The averagefilm thickness in the solid regions remained 0.3 mm.

Example 3

The nonwoven composite of example 1 was coated with 300 g/m² of 12 meltflow rate (MFR) low density polyethylene (LDPE) using a standardextrusion lamination process. The nonwoven was roll fed into a nipformed by a textured chill roller and a pressure roller such that thelower side of the nonwoven faced the textured chill roller and the upperside faced the pressure roller. Molten LDPE was applied to the lowerside of the nonwoven at the nip. The chill roll was patterned with araised grid design different from Example 2, where the high points ofthe textured surface were continuous and linear, and the low points weresquare-like and discontinuous. The pattern was a mixture of 4 mm and 9mm squares and the grid was approximately 1 mm in width and 1 mm indepth. An inverse texture of the chill roll was imparted to the lowerside of the nonwoven, meaning that the raised grid of the patterned nipresulted in a nonwoven composite with 4- and 9-mm raised squares and a1-mm wide recessed grid pattern. The recessed grid of the nonwovencomposite corresponds to the formation of the porous regions 200, whilethe raised squares correspond to the formation of solid regions 100. Inthe solid regions 100, the solid region cap layer 130 had an averagethickness of about 0.3 mm.

The nonwoven composite of Example 3 was heated by an infrared heater toa surface temperature of approximately 350° F. while constrained by aframe around all 4 sides, then cooled to near room temperature beforeremoving from the frame. After the heating and cooling, the nonwovencomposite exhibited a plurality of micropores in the porous regions, andthe porosity in the solid regions was essentially zero, meaning no poreswere found in the solid regions over the area surveyed. After heating,the solid regions look substantially unchanged from the unheated Example3, that is, the cap layer porosity remains essentially zero. The averagefilm thickness in the solid regions remained 0.3 mm.

Example 4

The nonwoven composite of example 1 was coated with 300 g/m² of 12 meltflow rate (MFR) low density polyethylene (LDPE) using a standardextrusion lamination process. The nonwoven was roll fed into a nipformed by a textured chill roller and a pressure roller such that thelower side of the nonwoven faced the textured chill roller and the upperside faced the pressure roller. Molten LDPE was applied to the lowerside of the nonwoven at the nip. The chill roll was patterned with athird raised grid design, where the high points of the textured surfacewere continuous and linear, and the low points were square-like anddiscontinuous. The squares were approximately 9 mm on each side and thegrid was approximately 1 mm in width and 1 mm in depth. An inversetexture of the chill roll was imparted to the lower side of thenonwoven, meaning that the raised grid of the patterned nip resulted ina nonwoven composite with 9-mm raised squares and a 1-mm wide recessedgrid pattern. The recessed grid of the nonwoven composite corresponds tothe formation of the porous regions 200, while the raised squarescorrespond to the formation of solid regions 130. In the solid regions100, the solid region cap layer 130 had an average thickness of about0.3 mm.

The nonwoven composite of Example 4 was heated by an infrared heater toa surface temperature of approximately 350° F. while constrained by aframe around all 4 sides, then cooled to near room temperature beforeremoving from the frame. After the heating and cooling, the nonwovencomposite exhibited a plurality of micropores in the porous regions, andthe porosity in the solid regions was essentially zero, meaning no poreswere found in the solid regions over the area surveyed. After heating,the solid regions look substantially unchanged from the unheated Example4, that is, the cap layer porosity remains essentially zero. The averagefilm thickness in the solid regions remained 0.3 mm.

Example 5

The nonwoven of example 1 was coated with 300 g/m2 of 12 melt flow rate(MFR) low density polyethylene (LDPE) using a standard extrusionlamination process. The nonwoven was roll fed into a nip formed by atextured chill roller and a pressure roller such that the lower side ofthe nonwoven faced the textured chill roller and the upper side facedthe pressure roller. Molten LDPE was applied to the lower side of thenonwoven at the nip. The chill roll was patterned with a raised stripesdesign, where the high points of the textured surface were continuousand linear, and the low points were also continuous and linear. Thestripes were 2.2 mm wide with a spacing of 3.2 mm and a depth of 1.4 mm.An inverse texture of the chill roll was imparted to the lower side ofthe nonwoven, meaning that the raised stripes of the patterned nipresulted in a nonwoven composite with recessed stripes. The recessedstripes of the nonwoven composite correspond to the formation of theporous regions 200, while the raised stripes correspond to the formationof solid regions 130. In the solid regions 100, the solid region caplayer 130 had an average thickness of about 0.3 mm.

The nonwoven composite of Example 5 was heated by an infrared heater toa surface temperature of approximately 350° F. while constrained by aframe around all 4 sides, then cooled to near room temperature beforeremoving from the frame. After the heating and cooling, the nonwovencomposite exhibited a plurality of micropores, and the porosity in thesolid regions was essentially zero, meaning no pores were found in thesolid regions over the area surveyed. After heating, the solid regionslook substantially unchanged from the unheated Example 5, that is, thecap layer porosity remains essentially zero. The average film thicknessin the solid regions remained 0.3 mm.

Example 6

The nonwoven composite of example 1 was coated with 300 g/m² of 12 meltflow rate (MFR) low density polyethylene (LDPE) using a standardextrusion lamination process. The nonwoven was roll fed into a nipformed by a chill roller and a pressure roller such that the lower sideof the nonwoven faced the chill roller and the upper side faced thepressure roller. Molten LDPE was applied to the lower side of thenonwoven at the nip. The chill roll was not patterned, which resulted ina smooth coating with no pattern of solid and porous regions.

The sound absorption coefficients of examples 1-6 are reported in FIG.7. Example 1, which is an uncoated nonwoven, consists of only porousregions and as such exhibits an almost purely absorptive acousticbehavior. Example 6, which is a coated nonwoven that has essentially noporosity, gives a typical resonant absorber absorption response; thatis, has high absorption centered around a narrow frequency band butlittle-to-no absorption at higher frequencies. Examples 2-5, whichcontain both solid regions and pores in the porous regions, providesuperior absorption over a wide range of frequencies over materials thathave essentially only solid or only porous regions. Further, changingthe pattern to tailor the porous area allows for control of the resonantfrequency and the high frequency absorption.

TABLE 1 Example Ice Detach Force (N) Air Permeability (cm³/s)/cm² 1 28.236 2 7.0 3.3 3 3.3 1.8 4 4.5 1.4 5 4.2 2.4 6 0.25 <0.1

Table 1 describes the ice detach force for examples 1 through 6. As canbe seen in the table, the presence of solid regions lowers the forcerequired to detach ice. In general, the greater the percentage of solidregion present in the nonwoven composite, the lower the force requiredto detach ice from the lower surface of the nonwoven composite. Table 1also lists the air permeability of the example nonwoven composites. Theair permeability of the nonwoven of Example 1 is the highest. Airpermeability of the nonwoven composites (Examples 2-5) is reducedrelative to the nonwoven itself by the presence of solid regions.Example 6 exhibited no measurable air permeability (<0.1 cm/s).

In summary, Examples 2-5 exhibited superior sound absorption to eithersingle layer nonwovens (such as Example 1) or nonwovens coated with asolid layer (Example 6). Their air permeability was lower than fromtypical mechanical perforation and stable in value for a window of heattreatments. Ice detach force was significantly lower than the uncoatednonwoven. Air permeability and ice detach force constitute a trade-offthat can be tuned via the embossing pattern and process conditions tomatch the application.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

What is claimed is:
 1. A nonwoven composite having an upper surface and a lower surface, the upper surface and the lower surface further defining a composite thickness, wherein the nonwoven composite comprises a plurality of solid regions and a plurality of porous regions, wherein the solid regions have an average surface area size of greater than about 1 mm², wherein the porous regions have an average surface area size of greater than about 1 mm², wherein the porous regions and solid regions form a pattern on the lower surface of the nonwoven composite, wherein the solid regions comprise a solid region nonwoven layer, an optional solid region polymer-fiber infused layer, and a solid region cap layer, wherein the solid region nonwoven layer has a first side and a second side, wherein the first side of the solid region nonwoven layer forms a portion of the upper surface of the nonwoven composite, wherein the solid region nonwoven layer comprises a plurality of first staple fibers and less than about 5% by volume of a first polymer. wherein the solid region polymer-fiber infused layer has a first side and a second side, wherein the solid region polymer-fiber infused layer is oriented such that the first side of the solid region polymer-fiber infused layer is adjacent the second side of the solid region nonwoven layer, wherein the solid region polymer-fiber infused layer comprises a plurality of the first staple fibers and the first polymer, wherein the solid region cap layer has a first side and a second side, wherein the solid region cap layer is oriented such that the first side of the solid region cap layer is adjacent the second side of the solid region polymer-fiber infused layer, wherein the second side of the solid region cap layer forms a portion of the lower surface of the nonwoven composite, wherein the solid region cap layer comprises the first polymer and less than about 5% by volume of the first staple fibers, wherein the average distance between first and second sides of the solid region cap layer is greater than about 65 μm, wherein the porous regions comprise a porous region nonwoven layer and a porous region polymer-fiber infused layer, wherein the porous region nonwoven layer has a first side and a second side, wherein the first side of the porous region nonwoven layer forms a portion of the upper surface of the nonwoven composite, wherein the porous region nonwoven layer comprises a plurality of the first staple fibers and less than about 5% by volume of a first polymer, wherein the porous region polymer-fiber infused layer has a first side and a second side, wherein the porous region polymer-fiber infused layer is oriented such that the first side of the porous region polymer-fiber infused layer is adjacent to the second side of the porous region nonwoven layer and the second side of the porous region polymer-fiber infused layer forms a portion of the lower surface of the nonwoven composite, wherein the porous region polymer-fiber infused layer comprises a plurality of the first staple fibers and the first polymer, wherein the porous region polymer-fiber infused layer comprises between about 15 and 85% by volume first polymer, wherein the porous region polymer-fiber infused layer comprises plurality of pores, and wherein the pores comprise a continuous path from the first side to the second side of the porous region polymer-fiber infused layer.
 2. The nonwoven composite of claim 1, wherein the solid regions and porous regions are present as a rectilinear grid.
 3. The nonwoven composite of claim 1, wherein the nonwoven composite further comprises a plurality of wall regions located between the solid regions and porous regions.
 4. The nonwoven composite of claim 1, wherein the solid region cap layer comprises essentially no pores.
 5. The nonwoven composite of claim 1, wherein the solid region cap layer comprises essentially no first staple fibers from the solid region nonwoven layer.
 6. The nonwoven composite of claim 1, wherein solid regions have an average first porosity and the porous regions have a second porosity and wherein the second porosity is at least 1000% greater than the first porosity.
 7. The nonwoven composite of claim 1, wherein the solid and porous regions form at least 80% by area of the lower surface of the nonwoven composite.
 8. The nonwoven composite of claim 1, wherein the solid regions comprise a solid region polymer-fiber infused layer.
 9. The nonwoven composite of claim 1, wherein the solid regions comprise between about 20 and 95% of the surface area of the lower surface of the nonwoven composite.
 10. A process for forming a nonwoven composite comprising: (a) forming a nonwoven layer comprising a plurality of first fibers and having a first surface and an opposite second surface, the first surface and the second surface further defining a nonwoven layer thickness; (b) obtaining a first polymer, wherein the first polymer comprises a thermoplastic polymer; (c) applying the first polymer to the second surface of the nonwoven layer, wherein the first polymer is molten, semi-molten, or solid; (d) applying pressure and optionally heat to the nonwoven layer and first polymer, wherein the first polymer and the second surface of the nonwoven layer are subjected to a textured surface embedding a portion of the first fibers from the nonwoven into the first polymer, and wherein the step (d) is concurrent with or after step (c), (e) optionally cooling the first polymer forming a nonwoven composite: wherein the nonwoven composite comprises an upper surface and a lower surface, the upper surface and the lower surface further defining a composite thickness, wherein the nonwoven composite comprises a plurality of solid regions and a plurality of porous regions, wherein the solid regions have an average surface area size of greater than about 1 mm², wherein the porous regions have an average surface area size of greater than about 1 mm², wherein the porous regions and solid regions form a repeating pattern on the lower surface of the nonwoven composite, wherein the solid regions comprise a solid region nonwoven layer, an optional solid region polymer-fiber infused layer, and a solid region cap layer, wherein the solid region nonwoven layer has a first side and a second side, wherein the first side of the solid region nonwoven layer forms a portion of the upper surface of the nonwoven composite, wherein the solid region nonwoven layer comprises a plurality of first staple fibers and less than about 5% by volume of a first polymer. wherein the solid region polymer-fiber infused layer has a first side and a second side, wherein the solid region polymer-fiber infused layer is oriented such that the first side of the solid region polymer-fiber infused layer is adjacent to the second side of the solid region nonwoven layer, wherein the solid region polymer-fiber infused layer comprises a plurality of the first staple fibers and the first polymer, wherein the solid region cap layer has a first side and a second side, wherein the solid region cap layer is oriented such that the first side of the solid region cap layer is adjacent the second side of the solid region polymer-fiber infused layer, wherein the second side of the solid region cap layer forms a portion of the lower surface of the nonwoven composite, wherein the solid region cap layer comprises the first polymer and less than about 5% by volume of the first staple fibers, wherein the average distance between first and second sides of the solid region cap layer is greater than about 65 μm, wherein the porous regions comprise a porous region nonwoven layer and a porous region polymer-fiber infused layer, wherein the porous region nonwoven layer has a first side and a second side, wherein the first side of the porous region nonwoven layer forms a portion of the upper surface of the nonwoven composite, wherein the porous region nonwoven layer comprises a plurality of the first staple fibers and less than about 5% by volume of a first polymer. wherein the porous region polymer-fiber infused layer has a first side and a second side, wherein the porous region polymer-fiber infused layer is oriented such that the first side of the porous region polymer-fiber infused layer is adjacent to the second side of the porous region nonwoven layer and the second side of the porous region polymer-fiber infused layer forms a portion of the lower surface of the nonwoven composite, wherein the porous region polymer-fiber infused layer comprises a plurality of the first staple fibers and the first polymer, wherein the porous region polymer-fiber infused layer comprises between about 15 and 85% by volume first polymer, wherein the porous region polymer-fiber infused layer comprises plurality of pores, and wherein the pores comprise a continuous path from the first side to the second side of the porous region polymer-fiber infused layer.
 11. The process of claim 10, further comprising: (f) subjecting the nonwoven composite to additional heat and optionally pressure such that a plurality of pores or additional pores form in the porous regions such that the solid regions have an average first porosity and the porous regions have a second porosity and wherein the second porosity is at least 1000% greater than the first porosity.
 12. The process of claim 10, wherein the nonwoven composite is molded into a non-planar three-dimensional shape.
 13. The process of claim 10, wherein the heat and pressure in step (d) is applied by a nip comprising a patterned roller and a pressure roller.
 14. The process of claim 10, wherein the pattern on the patterned roller is the inverse of the pattern on the lower surface of the nonwoven composite.
 15. The process of claim 10, wherein steps (c), (d), and (e) occur approximately simultaneously.
 16. The process of claim 10, wherein the solid regions comprise between about 20 and 95% of the surface area of the lower surface of the nonwoven composite.
 17. The process of claim 10, wherein the porous regions comprise between about 5 and 60% of the surface area of the lower surface of the nonwoven composite.
 18. The process of claim 10, wherein the solid regions and porous regions are present as a rectilinear grid.
 19. The process of claim 10, wherein the solid region cap layer comprises essentially no pores. 